01-6110 Detaching and attaching cylinder head
Preceding work:
Coolant drained.
Intake manifold removed (14-1421).
Exhaust manifold removed (14-0068).
Cylinder head cover removed (01-5014).
1 Rocker arm bolt 75 Nm.
2 Rocker arm
3 Cylinder head bolt Wrench socket 422 589 00 09 00,
re-usable up to shank length of max. 170 mm.
4 Cylinder head bolt Wrench socket 422 589 00 09 00,
re-usable up to shank length of max. 146 mm.
5 Cylinder head bolt Box wrench socket 403 589 02 03 00,
re-usable up to shank length of max. 111 mm.
Tightening torques: 1st stage 10 Nm,
2nd stage 50 Nm,
3rd stage 100 Nm,
4th stage 140 to 150 Nm,
5th stage 180 to 190 Nm,
6th stage 90° to 100° angle of
rotation.
6 Tappet rod
7 Cylinder head place down to the side; pay attention to tightening
diagram.
8 Centering sleeve
9 Cylinder head gasket replace, pay attention to note.
Tightening torques Nm
Injection pipes to pump and nozzle 25
Intake manifold 40
Cylinder head cover 25
Exhaust manifold 50
Rocker arm bracket to cylinder head 75
Data
Overall height of cylinder head when new 114.00
113.90
Permissible stock removal up to minimum height of 113.40
Permissible unevenness of lower contact face over a length of 150 mm 0.015
Permissible difference of parallelism of top to bottom contact face 0.1
Pressure-testing cylinder head in water with pressure of 2.5 bar
Nozzle projection Bosch Omap
0.60 - 0.135
OM 441, 442, 443 0.92 - 0.167
0.89 - 0.167
OM 441 LA, 442 A/LA, 443 A/LA,444 A/LA 0.82 - 0.157
Projection of pistons
to top edge of crankcase 0.07
0.43
Layout of injection pipes
OM 441
OM 441 LA
OM 442
OM 442 A
OM 442 LA
OM 443
OM 443 A
OM 443 LA
OM 444 A
OM 444 LA
Special tools
Detaching
1 Unscrew the union nut of the injection pipes at
the nozzle holder.
Box wrench 000 589 07 03 00
2 Unscrew the union nut of the injection pipes at
the injection pump. Counter-hold pipe connection.
Note
Do not bend injection pipes.
Box wrench 000 589 07 03 00
Serrated wrench 000 589 50 03 00
3 Pull leak oil pipes off the nozzle holder.
4 Unscrew rocker arm bolts (1) and take off rocker
arm bracket.
5 Take tappet rods out of the crankcase.
6 Unscrew cylinder head bolts (3 and 4).
Wrench socket 422 589 00 09 00
7 Unscrew cylinder head bolt (5) below the nozzle
holder.
Note
The cylinder head bolt (5) cannot be taken out when
the nozzle holder is in place.
Box wrench socket 403 589 02 03 00
8 Take off cylinder head.
Note
With injection nozzle installed, place cylinder head
down to the side. Injection nozzle projects at the
bottom of the cylinder head.
Attaching
1 Clean the tapped hose in th crankcase.
2 Clean the cylinder head contact surface and the
plane surface of the crankcase.
3 Fit the new cylinder head gasket over the
centering sleeves (8) onto the plane face of the
crankcase.
Note
- The crankcase contact surface and the liner collar
seat of reconditioned engines are machined, if
necessary.
- When replacing the cylinder head gasket (on
reconditioned engines), it is therefore necessary to
measure the piston projection.
- If the piston projection is less than 0.3 mm, install
the standard cylinder head gasket.
- If the piston projection is 0.3 mm or greater, install
a cylinder head gasket which is 0.1 mm thicker.
4 Fit cylinder head onto cylinder head gasket.
5 Measure the shank length of the cylinder head
bolts.
6 Lightly oil cylinder head bolts, screw in and
tighten with the wrench socket 422 589 00 09 00 in
the specified order in the following stages.
1st stage 10 Nm
2nd stage 50 Nm
3rd stage 100 Nm
4th stage 140 to 150 Nm
5th stage 180 to 190 Nm
6th stage 90° to 100° angle of rotation
Wrench socket 422 589 00 09 00
Note
- Use special wrench for the cylinder head bolt
below the nozzle holder.
- If a cylinder head bolt is tightened excessively
when installing, remove all of the six cylinder head
bolts, check for stretch and re-tighten starting with
stage 1.
Box wrench socket 403 589 02 03 00
7 Insert the tappet rods.
8 Fit on the rocker arm bracket, align rocker arms
to the valves and tappet rods. Screw rocker arm
bolts (1) tight, 75 Nm.
9 Set valve clearance (05-1122).
10 Install injection pipes (10) and bolt tight to
nozzle holder and injection pump, 25 Nm.
Box wrench socket 000 589 68 03 00
Note
Counter-hold thrust nut of injection pump.
Serrated wrench 000 589 50 03 00
Box wrench socket 000 589 68 03 00
11 Fit leak oil pipe onto the nozzle holder.
Note
The cylinder head bolts are no longer re-tightened.
